Universal electric vehicle charging adapter

Abstract: An adapter (10) for an electric vehicle (14) is provided which imposes an identification signal on the outlet voltage to inform the battery charger (16) of the characteristics of the outlet (e.g., the maximum current and voltage) to allow the battery charger (16) to charge at the maximum possible rate allowable by the outlet.

Description: The invention relates generally to electric vehicle power systems and more specifically to an adapter for connecting an on-vehicle battery charger with an electrical outlet wherein the adapter transmits certain electrical characteristics of the outlet to the charger. Electric vehicle battery systems typically employ charging facilities with unique features and greater power transfer capabilities than most conventional electrical outlets. Therefore, specially adapted recharging stations are provided with power supply capability coincident with the recharge capability of the electric vehicle power system. Nevertheless, it is desirable to have the capability to recharge electric vehicles using either specially adapted charging facilities or standard wall outlets if such a charging facility is unavailable. The specially adapted charging facilities may deliver current at a rate of about 230 volts and 30 amps while a standard wall outlet delivers 120 volts and 12 amps. It is desirable to produce an electric vehicle power system capable of being recharged anywhere in the world. One obstacle, however, lies in the different electrical services provided throughout the world. For example, the line voltage in the United States is 120 volts while in Europe it is 230 volts. Household-type appliances are known which transform the different outlet voltages to a common voltage to operate the appliance. However, in this method the power transfer capabilities of the outlets are not fully utilized. A special outlet is capable of handling a significantly higher current than a standard wall outlet and thus, a battery can be charged at a faster rate. If a battery charger attempts to charge through a standard wall outlet at the high current of a special outlet, current in excess of the ratings for the outlet and household wiring will flow thereby tripping a circuit breaker or blowing a fuse. JP-A-2 146 937 discloses a battery charger which is connected to a power supply outlet through a cable connector having a number of short-circuit terminals. A control circuit controls the flow of current into the battery charger according to a selection of one of the short circuit terminals, the selection being made by the user according to the type of power source. An abnormal current flow is thereby avoided. This document does not however disclose an adapter which incorporates the means to inform the battery charger of the characteristics of the power outlet without user intervention. DE-A-3 537 432 discloses an optical signal coupler including two modules between which optical signals can be transmitted in both directions. Each module includes a multiplexer and demultiplexer and a data store. In one embodiment of the coupler, an electrical connection runs parallel to the optical coupling. DE-A-4 114 921 describes an electrical plug connected to a cable having a plurality of individual leads. Connector pins are provided to make connection to corresponding connectors in a mating socket. An EEPROM is mounted in the plug to provide data parameters to the socket connectors in parallel to signals from a signal source connected to the plug. It is desirable to provide an adapter that informs the battery charger of the electrical characteristics of the outlet, thereby allowing the charger to fully utilize the power capabilities of the outlet. An object of the present invention is to allow a vehicle charger to maximise its charge rate based on the capabilities of the power supply. According to the present invention there is now provided an electric vehicle battery recharging system comprising a battery charger and a power line adapter for connecting an electrical power supply outlet to an electrical input of the electric vehicle battery charger, wherein the adapter comprises: a power line suitable for supplying the power to the battery charger and, connection means adapted for electrically connecting the power line to a specific electrical outlet with known electrical characteristics and to the electrical input of the battery charger and; the battery charger has means to adjust the charge rate by varying the amount of current drawn from the power supply outlet, characterised in that; the adapter further comprises electrical data storing means for storing data representing the electrical characteristics of the outlet to which the connection means is adapted to make connection; logic means for reading the electrical data from the data storing means and adapted to generate therefrom an identification signal representative of said electrical characteristics; and transmitting means coupled to said connection means for transmitting said identification signal to said battery charger, and the battery charger includes an identification logic circuit to provide the information used to determine the rate at which the charger draws current. One advantage of this invention is that a common battery charger can be used on vehicles throughout the world. A different adapter coded with different information is all that is needed to connect to different power supplies. Another advantage of the invention is that it allows redesign of charging facilities in the future along with the modification of the adapter without having to modify the battery charger. Another advantage of the invention is that by fully utilizing the power capability of the outlet to which the charger is connected, the time to recharge a battery is minimized. The invention will now be described further, by way of example, with reference to the accompanying drawings, in which: FIG. 1 is a plan view of the recharging system of the invention. FIG. 2 is a block diagram of the circuitry of the identification circuit of FIG. 1. FIG. 3 is an alternative embodiment of the adapter identification circuitry. FIG. 4 is a configuration for the identifier code word. Referring now to FIG. 1, an adapter 10 provides a link between an outlet receptacle 8 and an electric vehicle 14. Adapter 10 is comprised of a plug 19, power line 21, an identification box 22 and a connector 24. Battery charge unit 16, connector 24 and inlet receptacle 18 are preferably common to all vehicles 14. Due to the different variations of shape and capacity of outlet receptacles 8 throughout the world, a corresponding adapter 10 having a unique plug 19 is provided for each respective outlet receptacle 12. For example, in the U.S. and Canada the standard NEMA 5-15P plug 11 for an outlet rated at 120 volts and 12 amps would be provided. In addition, an adapter having a unique plug for various charging stations would also be provided. The United Kingdom and Continental Europe have plugs for outlets with standard 230 volts and 30 amp capabilities having slightly different geometries which use the BS 1363 and CE 7/7 standards as represented by 12 and 13, respectively. Thus, different adapters with unique plugs 19 are provided for recharging from each of the various types of outlets. Battery charger 16 is capable of adjusting the charge rate by varying the amount of current drawn from outlet 12 in response to the information received from powerline identification box 22. For example an adjustable current regulator may be used. Referring now to FIG. 2, adapter 10 has an identification box 22 which comprises a ground fault interrupt circuit 26 and an identification circuit 28 electrically connected to power line 21. Power line 21 is connected in series with ground fault interrupt circuit 12 which is of the type providing short-circuit protection by opening the circuit upon detection of a short circuit between the power line and ground. For example, a ground fault interrupt circuit for a standard U.S. 120 volt outlet is manufactured by Hubbell Inc. of Bridgeport, CT, model GFP6C15. Other such ground fault circuits are available for other electrical standards. Identification circuit 28 which is connected in parallel with power line 21 is powered by a power supply 20 which converts the power line voltage provided by power lines 21 to a predetermined D.C. voltage. As represented in FIG. 4, an identifier uniquely identifying the electrical capabilities of outlet 12 (e.g., voltage level, current level, and whether its alternating or direct current) is stored in an identifier code memory 32, preferably a non-volatile memory such as ROM. The codes contained in the memory 32 identify the maximum ratings of outlet to which adapter 10 is connected. Logic 34 reads the memory sequentially and converts the data to a series of pulses. A powerline carrier oscillator circuitry 36 converts the serial data into a amplitude modulated waveform which is then added to the powerline through a powerline interface 38. The waveform can be amplitude or frequency modulated, for example, as is known in the art. The power line voltage with the added data signal leaves adapter 10 and is received into electric vehicle 14. Powerline interface 40 in on-vehicle charger 16 is connected to power line 21 and is preferably comprised of a bandpass filter for isolating the modulated code data. A demodulator 42 connected to interface 40 receives the code data and converts it to serial data (i.e., digital code). An identification logic circuit 44 acting as a demultiplexer is connected to demodulator 42 and converts the serial data to parallel data. Identification logic 44 is connected to I/O latch 46 which provides the information as required to the charger circuit (not shown). The information is used to determine the rate at which the charger draws current from the outlet receptacle 8. In an alternative embodiment of FIG. 3, a transmitter 47 is used to transmit identification data via a transmission line 41 to a receiver 48 in charger 16. Transmitter 47, for example, comprises a light emitting device to convert the serial data to light pulses for transmission on a fiber optic cable. Receiver 48 reconverts the light pulses to serial data which is coupled to identification logic 44 for generating the identifier code. FIG. 4 represents the identifier code 50 which is comprised of a start bit 52 followed by a series of data 54 and end bit 56. Data 54 represent the electrical characteristics of the outlet to which the adapter is capable of being connected. For example, data 54 can be comprised of the voltage rating 58, current rating 60 and whether the signal is alternating or direct current as shown in 62. The protocol can, for example, follow the Society of Automotive Engineer's Standard SAE J1850. In operation, when battery recharging is needed, the vehicle is connected into an electrical outlet. A separate adapter is provided for every outlet to which the plug is likely to be connected. When identification circuit is energized the electrical characteristics of the outlet are transmitted to the recharger. The battery charger receives the data and determines the maximum rate at which it can charge.

Claims: An electric vehicle battery recharging system comprising a battery charger (16) and a power line adapter (10) for connecting an electrical power supply outlet (12) to an electrical input of the electric vehicle battery charger (16), wherein the adapter comprises: a power line (21) suitable for supplying the power to the battery charger and, connection means (19,24) adapted for electrically connecting the power line (21) to a specific electrical outlet with known electrical characteristics and to the electrical input of the battery charger and; the battery charger (16) has means to adjust the charge rate by varying the amount of current drawn from the power supply outlet (12), characterised in that; the adapter (10) further comprises electrical data storing means (32) for storing data representing the electrical characteristics of the outlet (12) to which the connection means (19, 24) is adapted to make connection; logic means (22) for reading the electrical data from the data storing means (32) and adapted to generate therefrom an identification signal representative of said electrical characteristics; and transmitting means (47) coupled to said connection means for transmitting said identification signal to said battery charger (16), and the battery charger (16) includes an identification logic circuit (44) to provide the information used to determine the rate at which the charger (16) draws current. A system as claimed in claim 1, wherein said transmitting means (47) includes a separate conductor for conducting said identification signal to said battery charger (16). A system as claimed in claim 1 or 2, wherein said identification signal includes the maximum voltage rating and maximum current rating of said outlet. A system as claimed in claim 1, further including a power supply means (20) coupled to said power line (21) for supplying power to said logic means (34). A system as claimed in claim 2, wherein said separate conductor is a fiber optic cable. A system as claimed in claim 1, further including imposing means (34,36,38) for imposing the identification signal upon the line voltage of said power line (21). A system as claimed in any one of the preceding claims, further comprising a ground fault interrupt means (26) connected in series with said power line (21) for opening the connection between said battery charger and said electrical outlet upon sensing a short circuit. A system as claimed in claim 6, wherein said imposing means (34,36,38) includes: serial means (34) for converting the stored characteristics to a serial communication signal; modulating means (36) coupled to said serial means (34) for modulating a carrier signal according to said serial signal to produce a modulated signal; transmitting means (38) coupled to said modulating means (36) for transmitting said modulated signal to said battery charger. A system as claimed in claim 8, wherein said modulating means (36) modulates the amplitude of said carrier signal. A system as claimed in claim 8, wherein said modulating means (36) modulates the frequency of said carrier signal. A system as claimed in any one of the preceding claims wherein the battery charger (16) has; filter means (40) for isolating said identification signal; demodulation means (42) coupled to said filter means (40) for demodulating said identification signal; demultiplexing means (44) coupled to said demodulation means (42) for converting said identification signal into the individual electrical characteristics of said outlet; and latch means (46) coupled to said demultiplexing means (44) for controlling said battery charger (16). A method for recharging a battery of an electric vehicle comprising the steps of: connecting an electric input of a battery charger (16) to a power supply outlet (12) through a power line adapter (10) which includes a power line (21) suitable for supplying the power to the battery charger, the adapter including connection means (19, 24) adapted for electrically connecting the power line (21) to a specific electrical outlet with known electrical characteristics; and adjusting the charge rate by varying the amount of current drawn from the power supply outlet (12), characterised in that the method further comprises; storing in the adapter (10) data representing the electrical characteristics of the outlet (12) to which the connection means is adapted to make connection; reading the stored data and generating therefrom an identification signal representative of the said electrical characteristics; transmitting the identification signal to the battery charger; and adjusting the battery charge rate based upon said electrical characteristics of said outlet.

Inventors: BROWN ROBERT KENNETH, TOEPFER CRAIG BLAIR, BROWN, ROBERT KENNETH, TOEPFER, CRAIG BLAIR
Applicants: FORD FRANCE, FORD MOTOR CO, FORD WERKE AG, FORD FRANCE S. A., FORD MOTOR COMPANY LIMITED, FORD-WERKE AKTIENGESELLSCHAFT
Application year: 1994
Main classification: B60L11
IPC codes: H02J7, B60L11, H01R13, H01R27